Structure installation method

ABSTRACT

A flexible bag is interposed between a concrete slab bearing track rails and a base structure of a railway road bed, relative to which the slab is temporarily held apart, and then fluid cement mortar is fed into the bag to infate the same and form a pliable, bag-confined mass of mortar which snugly fits the space between the slab and base structue and, upon hardening, forms a strong and firm member whereby the slab is installed on the base structure.

waited @taies Patent Inventors Appl. No.

Filed Putented Assignee Priorities lrntnm Matsullmm Tokyo-to;

Vutelun Sintoh, Tokyo-to; Yosllilt'o Hlguehl, Toltyarw; Shligeru Tumum,Tokyu: Ynsuo lulmlzu. ichllmwnmhl, mll oil Jmpn 933,406

.lume 16, 1969 Nov. 23, 197B Nlppon lKollmyu Tetsudo Toliym, Japan June20, 1968 Japan June 20, 1968, Japan, No. 43/42236 STRUCTURElNSTAlLlLATlON METHOD l S Claims, l5 Drawing Figs.

US. Cl 23S/l, 52/744, 23S/283, 264/220 Int. CI EQulbQj/OVQ lill3,622,072

"[50] FieldoiSearch 23S/2,1, 283; l04/l, 2; 264/220, 45; 52/744; 2l4/220, 45

[56] References Cited y UNITED STATES PATENTS '2,875,953 3/1959 Weberetal. 238/2 3,382,815 5/1968 Higuchi et aL... l04/3 3,432,098 3/1969Sato 238/283 3,442,222 5/l969 Olson etal l04/3 Primary Examiner- ArthurL. La Point Assistant Examiner-Richard A. Bertsch Attorneys-Robert E.Burns and Emmanuel J. Lobato ABSTRACT: A flexible bag is interposedbetween a concrete slab bearing track rails and a base structure of arailway road i'bed, relative to which the slab is temporarily heldapart` and then fluid cement mortar is fed into the bag to infate thesame and form a pliable, bag-confined mass of mortar which snugly ts thespace between the slab and base structue and, upon hardening, forms astrong and rm member whereby the slab "isinsiailgqqnsh base structure.

PATENTEUNuv 23 Ism SHEET B UF 6 FIG.

FIG. I5

STRUCTURE INSTALLATION METHOD BACKGROUND OF THE INVENTION This inventionrelates to techniques in installing relatively heavy structures and moreparticularly to a new and improved method for installing an upperstructure on a lower structure with a specific positional relationthereto.

One example, although by no means the only example, of such installationis the installation of concrete slabs bearing railway track rails on abase structure. In such an installation it has heretofore been necessaryto use concrete forms and accompanying structures. Furthermore, suchinstallations have heretofore required a high degree of skill. in spiteof which the supported state of the upper structure has not been uniformin many cases, particularly where such support is required over a longdistance.

SUMMARY OF THE INVENTION It is another object of the present inventionto provide a simple installation method whereby an upper structure canbe supported positively and securely on a lower structure.

Another object of the invention is to provide a method as stated abovewhereby the upper structure can be thus installed rapidly in uniformlysupported state with relative simple equipment and without concreteforms and the necessity for high skill, the ultimate object being toreduce the cost and time of installation of such structures.

According to the present invention in one aspect thereof, brieflysummarized there is provided a method as stated above wherein at leastone flexible bladderlike bag is interposed between a lower structure andan upper structure held temporarily thereabove and is inflated with ahardenable fluid substance forced into the bag, whereby a pliable,bag-confined mass of the fluid substance fits intimately and firmlybetween the upper and lower structures and, upon hardening, constitutesa member for positively and securely supporting the upper structure onthe lower structure.

According to the present invention in another aspect thereof, there isprovided an installation method wherein a flexible bag filled with ahardenable fluid substance is partly interposed in the space between theupper and lower structures temporarily held at specific relativepositions, and the remainder part of the bag, which is disposed outsideof the space between the structures, is squeeze toward the space tocompel the fluid substance therein to move into the part of the bagbetween the upper and lower structures.

The nature, principle, details, and utility of the invention will bemore clearly apparent from the following detailed description withrespect to preferred embodiments of the invention when read conjunctionwith the accompanying drawings, in which like parts are designated bylike reference numerals.

BRIEF DESCRIPTION OF THE DRAWINGS In the drawings:

FIG. l is a perspective view, with parts cut away and foreshortened,indicating one example of practice embodying the invention;

FIGS. 2 and 3 are perspective views respectively showing parts ofpolyethylene bags for injecting mortar thereinto and for inspection forthe example illustrated in F IG. l;

FIG. d is a perspective view, with parts cut away and foreshortened,indicating another example of practice of the invention;

FIGS. 5 and 6 are perspective views respectively showing parts ofpolyethylene bags for injecting mortar thereinto and for inspection forthe example illustrated in FIG. 4;

FIG. 7 is a perspective view, with parts cut away and foreshortened,indicating still another example of practice of the invention;

FIGS. 8 and 9 are perspective views respectively showing parts ofpolyethylene bags for injecting mortar thereinto and for inspection forthe example illustrated in FIG. '7;

FIG. I0 is a perspective view showing one example of apparatus forinjecting mortar into polyethylene bags in accordance with theinvention;

FIGS. 11 through I4, inclusive, are cross-sectional views indicatingprogressive steps in one example of practice of the invention in anotheraspect thereof; and

FIG. l5 is a perspective view showing one example of a second pressingdevice suitable for use in the method indicated in FIGS. 1l through 14,inclusive.

DETAILED DESCRIPTION In one example of practice of the invention asapplied to a railway track which does not require maintenance and asillustrated in FIGS. l, 2, and 3, a concrete base structure I isprovided as a lower structure and has along its center in thelongitudinal direction a plurality of upright projections Ia fixedintegrally to the base structure 1 at specific space intervals.

A precast concrete slab 2 for supporting the track rails thereon is tobe supported on the base structure l as described hereinbelow and isprovided with slot holes 2a or cutouts 2a at positions confrontingcorresponding projections Ia, which have dimensions such that eachprojection can fit loosely in the corresponding hole 2a or cutout 2a,.

The slab 2 is mounted by suspending it above the base structure l sothat the projections la fit into the slot holes 2a and cutouts 2a, atspecific intervals. At the same time, wedges (not shown) are insertedbetween the base structure l and slab 2 thereby to mount the slab 2temporarily on the base structure with a suitable spacing therebetween.During this assembly, packing members 3 are inserted between the sidesof the holes 2a or cutouts 2al and their corresponding projections lathereby to determine the relative positioning of the base structure andthe slab.

The slab 2 is provided beforehand along the two lateral sides of itslower surface in the longitudinal direction thereof with two rubber mats4. A series of polyethylene bags 5 of tubular strip shape as describedhereinafter is next inserted between the lower surface of each rubbermat 4 and the upper surface of the base structure l.

One end of each bag 5 and the nearest end of the adjacent bag 5 arecommunicatively connected to respectively opposite open ends of atubular box 6 made of vinyl chloride plate and provided on its upperpart with a pipe fitting 6a including a valve for supplying cementmortar into the box and bags. The other end (i.e., the end opposite theend connected to a box 6) of each bag 5 is communicatively connected toan open end of a vinyl chloride box 7 closed at the other end and havingat its upper part an inspection hole to which an inspection tube 7a iscommunicatively connected.

A feedpipe connected at one end to the discharge aperture of a cementmortar feeding hopper (not shown) is connected at the other end to eachpipe fitting 6a. Each inspection tube 7a is supported substantiallyvertically by suitable means.

In operating the apparatus of the above described organization cementmortar which has been kneaded in a mortar mixer is introduced throughthe above-mentioned feeding hopper, the feedpipe, pipe fitting 6a, andbox 6 into the pair of bags 5 connected to each box 6. All bags 5 arethereby filled and inflated with mortar, thereby uniformly andelastically supporting the slab along its entire length. This desiredstate of inflation of the bag 5 can be detected by observing that themortar has risen within the inspection pipes 7a, whereupon the feedingof the mortar into the bags S is stopped.

Each of the feedpipes connected to the pipe fittings 6a and theinspection tubes 7a is then constricted at two places, and the hopperfor feeding mortar and tube support means are removed and transferred tothe succeeding installation site. When the mortar thus injected into thebags 5 begins to set and loses its viscosity, each bag 5 is transverselycut at sections in the vicinity of the boxes 6 and 7, which are thenremoved for circulatory reuse at another work site.

Examples of cement mortars suitable for use in accordance with the abovedescribed installation method of the invention are rapidahardeningcement (also known as high early strength cement) mortars, Portlandcement mortars in which accelerators have been admixed, resin mortars,and cement mortars in which reinforcing materials have been admixed incases where high strength is required.

In another embodiment of the invention as illustrated in FIGS. 4, 5, and6, the mutually nearest ends of adjacent polyethylene bags S arecommunicatively connected to the open opposite ends of a tubular box 6-1made of vinyl chloride plate and having a mortar injecting nozzle pipe6a,. The other end of each of these two bags S and the nearest end ofthe bag adjacent to said other end are communicatively connected torespective opposite, open ends of a vinyl chloride box 7-I and therebycommunicatively connected to respective separate chambers formed by apartition 7a, within the box 7-1. The two chambers are respectivelyconnected through inspection holes 7bl to inspection tubes 7c,.

The other parts of the apparatus are the same as or similar to those inthe preceding example illustrated in FIGS. 1, 2, and 3 and are therebydesignated by like reference numerals. The operation of the apparatus inthis example is the same as that in the preceding example. Accordingly,description of the parts common to the two examples and of the operationwill be omitted.

In a further embodiment of the invention as illustrated in FIGS. 7, 8,and 9, the ends of each polyethylene bag 5 are tapered in thickness andbent approximately perpendicularly upward and thus held by holdingmembers l to form riser parts which are respectively provided with anintegrally formed fcedpipe 6-2 and an integrally fonned inspection tube7-2, which are held substantially upright. The nearest ends of adjacentbags are bonded at their lower surfaces to a common polyethylene sheet 8by adhesive members 9, thereby being coupled by a connection structurewhich is made of the same material as the bags 5. Accordingly, a featureof this example is that all connection structures have pliabilty andflexibility similar to those of the main bag structures, whereby aseries of several bags in the above-described connected state can befolded into a compact body which can be conveniently and easilytransported, stored, and handled. The other parts of the apparatus arethe same as or similar to those of the preceding examples and areaccordingly designated by like reference numerals.

An example of a mortar-feeding device suitable for use in supplyingcement mortar into the polyethylene bags 5 in an apparatus as, forexample, that described above with reference to FIGS. I, 2, and 3, isillustrated in FIG. l0. This device comprises, essentially, a pair oflaterally left and right hoppers I2 supported by horizontal top frame 13to the four corners of which the upper ends of four support legs 1l ofvariable length are fixed, Additional support legs I4 are also fixed ina suspended state to the top frame I3 and, at their lower parts,rotatably support wheels for running on left and right rails (not shown)laid on the aforementioned slab 2. The lower discharge outlets of thehoppers I2 can be connected by mortar-feeding pipes 16 respectively tothe aforementioned pipe fittings 6a of a pair of left and right boxes 6for supplying mortar into the bags 5 connected thereto.

In using the mortar feeding device of the above-described organization,the wheels 15 are utilized to transport the entire device to a desiredposition, and then the legs ll are extended to a secure footing on theaforementioned base structure l or the ground on both sides of the slab2 thereby to fix the hoppers l2 relative to the ground. The dischargeoutlets of the hoppers l2 and the pipe fittings 6a of the boxes 6 arethen connected by feedpipes I6, and cement mortar supplied into thehoppers is introduced into the bags 5.

After the bags 5 connected to these boxes 6 have been filled andinflated with mortar. the feeding pipes 16 are disconnected from thepipe fittings 6a, and the legs Il are shortened und separated from thebuse structure l or the ground. The

mortar-feeding device is then transferred to the succeedingmortar-feeding position.

In accordance with the present invention in another aspect thereof, asmentioned hereinbefore, a flexible bag or bladder filled with ahardenable fluid substance is inserted between a lower structure and anupper structure with a part of the bladder outside of the space betweenthe two structures, and then this bladder part is squeezed so as toforce the fluid therein toward that space and thereby to install theupper structure fixedly relative to the lower structure.

The manner in which this technique of installation may be carried out inpractice will now be described with respect to a specific example ofpractice as illustrated in FIGS. l1 through 15, inclusive. Therequirement in this example is to install a precast concrete slab 22bearing rails 3l of a track on a concrete base structure 2l at aspecific height thereabove.

The slab 22 is first positioned and temporarily held above the basestructure 2l at the required height thereabove by means such as wedges(not shown) inserted between the slab and a precast concrete bearing pad23 temporarily placed on the base structure 2l. A rubber mat 24 issecured to the lower surface of the slab 22 in a position to face thebearing pad 23. A timber pad or block 26 is temporarily placed on thebase structure 2l to support a first pressing device 27 in a positionoutside of the laterally outer edge of the slab 22.

A polyethylene bag 25 filled with cement mortar in fluid state isinserted partly between the base structure 2l and the slab 22 so that apart of the bag projects outwardly from the lateral edge part of theslab 22. The outer part of the bag 25 thus projecting outwardly isclamped between an upper plate 27b and 27a of the first pressing device27, which is essentially of dihedral form comprising the upper and lowerplates 27b and 27a hinged along a line 27C of intersection.

In addition to the first pressing device 27, use is made of a secondpressing device 28 having a channelshaped attachment member 28acomprising an upper flange 28a a lower flange 28413, and a web joiningthese flanges. This attachment member 28a is adapted to engage with thelateral edge part ofthe slab 22 and is held in the engaged state by apin 29 passed through a pin hole 28a2 drilled through the upper flange28al near the free edge thereof. The pin 29 is chained by a chain 30 toa part ofthe upper flange 28aI to prevent loss thereof.

The free edge of the lower flange 28a;i is hinged (28C) therealong toone edge of a pressing plate 28h. A support member 28d is fixed at itslower part to an edge of the pressing plate 28h parallelly opposite thehinged edge and supports at its upper part a horizontal force-applyingmember 28e.

In the installation procedure, the attachment member 28a is fitted ontoand engaged with the laterally outer edge part of the slab 22, and thenthe pin 29 is inserted through the pinhole 28a2 and caused to catchagainst a shoulder 22a of the slab. The free or distal end of thepressing plate 28h is placed in contact with the upper part of the bag25 at a part thereof in the vicinity of the laterally outer edge of theslab 22.

Then, after the bag 25 and the first and second pressing devices 27 and28 have been set in place as indicated in FIG. I1, a force such as thatdue to a weight of a specific weight value is applied to the upper plate27b of the first pressing device 27 thereby to force this upper platetoward the lower plate 27a as indicated in FIG. l2. Consequently, themortar within the outwardly projecting part of the bag 25 is squeezedtoward the part ofthe bag interior directly below the slab 22.

Then, as indicated in FIG. 13, a weight of specific weight value (notshown) is placed on the force-applying member 28e of the second pressingdevice 28 to cause the pressing plate 28b to press downwardly with arotational stroke about the hinged edge 28C on the bag 25. As a result,the bag directly below the slab 22 is forcibly inflated by the mortartherewithin thus pressurized and thereby firmly supports the slab on thebearing pad 23. At the same time. the free or dislul edge of thepressing plate 28h cuts off the outwardly projecting purt ofthe bag 25.

Then, when the mortar in the bag 25 hardens, the first pressing device27 is removed together with the cut off part of the bag, At the sametime, the pin 29 is extracted, and the channel-shaped attachment member23a of the second pressing device 28 is disengaged from the edge part ofthe slab 22 thereby to disconnect the pressing device 2B from theinstalled structures. The two pressing devices 2'7 and 28 can then betransferred to another work position.

For the mortar used in the bag 25, any of the aforemen tioned mortarssuitable for use in the examples described with reference to FIGS. lthrough l0 can be used.

lt should be understood, of course, that the foregoing disclosurerelates to only preferred embodiments of the invention and that it isintended to cover all changes and modifications of the examples of theinvention herein chosen for the purposes of the disclosure, which do notconstitute departures from the spirit and scope of the invention.

We claim:

l. A method of installation of an upper structure on and in a specificposition relative to a lower base structure, which comprises, incombination, the steps of temporarily holding said upper structureimmovably in said position; inserting a resilient plate under said upperstructure thereby to establish an elasticity between said upperstructure and base structure; interposing a flexible bladderlilte bagbetween said resilient plate and base structure to form a uniforifnsupport layer between said structures, said bag containing a hardenablefluid substance therein and being provided with a portion projectingoutward of said upper structure; squeezing said bag at said projectingportion thereof so as to compel said fluid substance to be squeezedtoward part of the bag under said upper structure thereby to inflatesaid part of the bag and form a pli able, bag-confined mass of the fluidsubstance in firm contact with said resilient plate and lower basestructure; and causing said fluid substance to harden thereby to causethe upper structure to be supported firmly on the lower structurethrough said resilient plate and said mass of the substance thusinterposed and hardened therebetween.

2. A method of installation as set forth in claim l. in which saidsqueezing is carried out in two steps comprising a first 4step includingthe pressing of a first device for applying pressure to an outermostportion of said projecting bag portion, and a second step including thepressing of a second device for applying pressure to an inner portion ofsaid projecting bag portion to urge said hardenable fluid within saidprojecting portion to a position between said resilient plate and base.

3. A method of installation as set forth in claim l, in which said stepof inserting a resilient plate is performed by placing a rubber platebeneath said upper structure, and said step of interposing a flexiblebag between said plate and base is performed by disposing a syntheticresin bag therebetween.

4. A method of installation as set forth in claim l, further comprisingthe step of selecting said hardenable fluid sub stance from the groupconsisting of rapid hardening cement mortars, Portland cement mortarshaving an accelerator mixed therein, resin mortars, and cement mortarshaving reinforced materials mixed therein.

5. A method of installation of an upper structure on and in a specicposition relative to a lower base structure, which comprises the stepsof temporarily holding said upper structure immovably in said position;interposing a flexible bladderlike bag between said upper sn'ucture andbase structure to form a uniform support layer between said structures,said bag con` taining a hardenable fluid substance therein and beingprovided with a portion projecting outward of said upper structure;squeezing said bag at said projecting portion thereof so as to compelsaid fluid substance to be squeezed toward part of the bag and form apliable, bag-confined mass of the fluid substance in rm contact withsaid upper and lower structures; and causing said fluid substance toharden thereby to cause the upper structure to be supported firmly onthe lower structure through said bag-confined mass thus interposed andhardened therebetween; m n

1. A method of installation of an upper structure on and in a specificposition relative to a lower base structure, which comprises, incombination, the steps of temporarily holding said upper structureimmovably in said position; inserting a resilient plate under said upperstructure thereby to establish an elasticity between said upperstructure and base structure; interposing a flexible bladderlike bagbetween said resilient plate and base structure to form a uniformsupport layer between said structures, said bag containing a hardenablefluid substance therein and being provided with a portion projectingoutward of said upper structure; squeezing said bag at said projectingportion thereof so as to compel said fluid substance to be squeezedtoward part of the bag under said upper structure thereby to inflatesaid part of the bag and form a pliable, bagconfined mass of the fluidsubstance in firm contact with said resilient plate and lower basestructure; and causing said fLuid substance to harden thereby to causethe upper structure to be supported firmly on the lower structurethrough said resilient plate and said mass of the substance thusinterposed and hardened therebetween.
 2. A method of installation as setforth in claim 1, in which said squeezing is carried out in two stepscomprising a first step including the pressing of a first device forapplying pressure to an outermost portion of said projecting bagportion, and a second step including the pressing of a second device forapplying pressure to an inner portion of said projecting bag portion tourge said hardenable fluid within said projecting portion to a positionbetween said resilient plate and base.
 3. A method of installation asset forth in claim 1, in which said step of inserting a resilient plateis performed by placing a rubber plate beneath said upper structure, andsaid step of interposing a flexible bag between said plate and base isperformed by disposing a synthetic resin bag therebetween.
 4. A methodof installation as set forth in claim 1, further comprising the step ofselecting said hardenable fluid substance from the group consisting ofrapid hardening cement mortars, Portland cement mortars having anaccelerator mixed therein, resin mortars, and cement mortars havingreinforced materials mixed therein.
 5. A method of installation of anupper structure on and in a specific position relative to a lower basestructure, which comprises the steps of temporarily holding said upperstructure immovably in said position; interposing a flexible bladderlikebag between said upper structure and base structure to form a uniformsupport layer between said structures, said bag containing a hardenablefluid substance therein and being provided with a portion projectingoutward of said upper structure; squeezing said bag at said projectingportion thereof so as to compel said fluid substance to be squeezedtoward part of the bag under said upper structure thereby to inflatesaid part of the bag and form a pliable, bag-confined mass of the fluidsubstance in firm contact with said upper and lower structures; andcausing said fluid substance to harden thereby to cause the upperstructure to be supported firmly on the lower structure through saidbag-confined mass thus interposed and hardened therebetween.